Electrical power system for a vehicle

ABSTRACT

A vehicle electrical power system includes a phase module assembly of a multi-phase inverter. The phase module assembly includes first and second flat laminated busbars extending in orthogonal planes. The phase module assembly also includes one or more transistors that convert direct current into one phase of a multi-phase alternating current of the multi-phase inverter, and to output the phase of the multi-phase alternating current to the load. The phase module assembly also includes one or more capacitors conductively coupled with the internal positive and negative terminal connectors and with the external positive and negative bushings configured to be conductively coupled with the power source of direct current. The assembly can be useful for vehicles because the components of the system are configured to carry large amounts of current in a more reliable and sustainable manner.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/431,382, filed on 4 Jun. 2019, which claims priority to U.S.Provisional Application No. 62/680,265, filed 4 Jun. 2018. The entiredisclosures of these applications are incorporated herein by reference.

FIELD

Embodiments of the subject matter disclosed herein generally relate toelectric power systems for vehicles.

BACKGROUND

Inverters convert direct current (DC) into alternating current (AC).Some inverters include multiple phase modules that each convert aportion of the DC into a different phase of the AC. For example, someinverters include three phase modules that each create a different phaseof AC (for 3-phase AC power).

Some vehicle power systems include inverters that power significantloads. For example, some vehicles may include inverters that powertraction motors that propel the vehicles. These inverters generate heatduring operation, and some known inverters are air cooled, having eithercapacitors integrated into standalone inverter modules or a bank ofcapacitors connected to a laminated bus structure (which then connectsto phase modules to form the inverter). In either situation, thecapacitors may be fitted with separation caps that take up significantvolume and weight. Additionally, the busbars of these systems can takeup significant volume and weight.

BRIEF DESCRIPTION

In one embodiment, a vehicle is provided that includes a chassis orhull, and a vehicle electrical power system operably disposed onboardthe chassis or hull. The power system includes a vehicle electrical loadthat comprises at least one of a vehicle motor or a braking resistor.The power system also includes a phase module assembly of a multi-phaseinverter. The phase module assembly includes a first flat laminatedbusbar elongated along a first direction, including a positive layer, anegative layer, and a load layer configured to be conductively coupledwith the load. The first flat laminated busbar includes internalpositive and negative terminal connectors for connecting the first flatlaminated busbar to a second laminated flat busbar. The second laminatedflat busbar includes positive and negative layers extending in a planethat is orthogonal to the first direction of the first laminated flatbusbar. The second laminated flat busbar includes external positive andnegative bushings configured to be conductively coupled with a powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assembly also includes one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assembly also includesone or more capacitors conductively coupled with the internal positiveand negative terminal connectors and with the external positive andnegative bushings configured to be conductively coupled with the powersource of direct current.

In one embodiment, a vehicle power supply system includes plural phasemodule assemblies each including a first flat laminated busbar elongatedalong a first direction, including a positive layer, a negative layer,and a load layer configured to be conductively coupled with a vehicleload. The first flat laminated busbar includes internal positive andnegative terminal connectors for connecting the first flat laminatedbusbar to a second laminated flat busbar. The second laminated flatbusbar includes positive and negative layers extending in a plane thatis orthogonal to the first direction of the first laminated flat busbar.The second laminated flat busbar includes external positive and negativebushings configured to be conductively coupled with a vehicle powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assemblies also include one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assemblies alsoinclude one or more capacitors conductively coupled with the internalpositive and negative terminal connectors and with the external positiveand negative bushings configured to be conductively coupled with thepower source of direct current. The phase module assemblies areconductively coupled with the power source to separately receivedifferent portions of the direct current and to separately generatedifferent phases of the multi-phase alternating current for the load.

In one embodiment, a vehicle power supply system includes plural phasemodule assemblies each including a first flat laminated busbar elongatedalong a first direction, including a positive layer, a negative layer,and a load layer configured to be conductively coupled with a vehicleload. The first flat laminated busbar includes internal positive andnegative terminal connectors for connecting the first flat laminatedbusbar to a second laminated flat busbar. The second laminated flatbusbar includes positive and negative layers extending in a plane thatis orthogonal to the first direction of the first laminated flat busbar.The second laminated flat busbar includes external positive and negativebushings configured to be conductively coupled with a vehicle powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assemblies also include one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assemblies alsoinclude one or more capacitors conductively coupled with the internalpositive and negative terminal connectors and with the external positiveand negative bushings configured to be conductively coupled with thepower source of direct current. The phase module assemblies areconductively coupled with the power source to separately receivedifferent portions of the direct current and to separately generatedifferent phases of the multi-phase alternating current for the load.The phase module assemblies also include a joining busbar connecting thephase module assemblies and configured to be conductively coupled withone or more bulk capacitors and one or more external cables of the powersource.

BRIEF DESCRIPTION OF THE DRAWINGS

The presently described subject matter will be better understood fromreading the following description of non-limiting embodiments, withreference to the attached drawings, wherein below:

FIG. 1 is a schematic illustration of one embodiment of an inverterstack assembly;

FIG. 2 is a schematic illustration of another embodiment of an inverterstack assembly;

FIG. 3 illustrates a circuit diagram of a power supply system;

FIG. 4 illustrates a circuit diagram of one embodiment of a phase moduleassembly shown in FIGS. 2 and 3;

FIG. 5 illustrates a perspective view of one embodiment of the phasemodule assembly shown in FIGS. 2 through 4;

FIG. 6 illustrates a perspective view of the inverter stack assemblyshown in FIG. 2;

FIG. 7 illustrates a closer view of the top of the inverter stackassembly shown in FIG. 6;

FIG. 8 illustrates a top view of one embodiment of plates of the phasemodule assembly shown in FIG. 1 connected with a heat sink;

FIG. 9 illustrates a side view of the heat sink shown in FIG. 8;

FIG. 10 illustrates a cross-sectional view of one embodiment of thephase module assembly shown in FIG. 1 disposed inside the exteriorhousing shown in FIG. 6;

FIG. 11 illustrates a perspective view of one embodiment of a back sideof a vertical busbar shown in FIG. 5; and

FIG. 12 is a schematic illustration of a vehicle.

DETAILED DESCRIPTION

The inventive subject matter described herein provides a more compactand lightweight air-cooled traction inverter system for loads such asheavy duty vehicles. Not all embodiments of the inventive subject matterdescribed herein is limited to heavy duty vehicles. One or moreembodiments of the inverter systems described herein can be used topower propulsion systems (e.g., motors) of a variety of vehicles, suchas traction motors of rail vehicles (e.g., locomotives), traction motorsof automobiles, motors that rotate propellers of marine vessels,traction motors of mining vehicles, motors of other off-highway vehicles(e.g., vehicles that are not legally permitted and/or are not designedfor self-propulsion along public roadways), etc.

The inverters described herein can utilize capacitors that areintegrated into a laminated busbar to form the DC link for a set ofphase module assemblies of the inverter, which can be configured to makeup two or more inverter and/or chopper functions. The phase moduleassemblies reduce commutation inductance and achieve higher powerdensities of a multiple inverter structure connected to a distributed DClink arrangement, while remaining reliable. The phase module assembliesalso can improve switching performances of silicon (Si) and siliconcarbide (SiC) high-power modules used in high power drives and gridconnected power inverters.

FIG. 1 is a schematic illustration of one embodiment of an inverterstack assembly 100 of a vehicle. The inverter stack assembly includes asingle DC link busbar 102 with integrated capacitors 104. The inverterstack assembly can be used in a powered system, such as a vehicle, topower loads such as traction motors. The inverter stack assemblyincludes the single DC link busbar with nine integrated capacitors thatsupply two multi-phase inverter assemblies 106, 108, an auxiliaryinverter assembly 110 (“Aux1” in FIG. 1), and a chopper 112 (“BC_1” inFIG. 1). Each of the inverter assemblies can be a three-phase inverterwith plural (e.g., three) phase module assemblies 114.

The phase module assembly of the first inverter assembly that is labeledInv1_phA can produce a first phase of AC to a first load (e.g., atraction motor), the phase module assembly of the first inverterassembly that is labeled Inv1_phB can produce a second phase of AC tothe first load, and the phase module assembly of the first inverterassembly that is labeled Inv1_phC can produce a third phase of AC to thefirst load.

Similarly, the phase module assembly of the second inverter assemblythat is labeled Inv1_phA can produce a first phase of AC to a secondload (e.g., another traction motor), the phase module assembly of thesecond inverter assembly that is labeled Inv1_phB can produce a secondphase of AC for the second load, and the phase module assembly of thesecond inverter assembly that is labeled Inv1_phC can produce a thirdphase of AC for the second load. In one embodiment, the chopper may be abrake chopper of a vehicle. The auxiliary inverter assembly may generateAC for loads that do work other than propelling the vehicle. A bulkcapacitor 116 optionally can be included to increment the totalcapacitance and current capability of the stack of inverter assemblies.The bulk capacitor can be one or more capacitors that are conductivelycoupled with multiple phase module assemblies and/or are connectedacross the DC supply lines of one or more (or all) of the inverterassemblies.

FIG. 2 is a schematic illustration of another embodiment of an inverterstack assembly 200. The inverter stack assembly 200 includes two DC linkbusbars 202, 204 that are connected by a joining busbar 206, where eachof the busbars 202, 204 includes four integrated capacitors 104, andthat supply DC current to the inverter assemblies 106, 108, theauxiliary inverter assembly 110, and the chopper 112. The joining busbar206 may be an interconnecting lamination (e.g., a laminated busbar) inone embodiment. The bulk capacitor 116 is located between the inverterassemblies 106, 108 and between the busbars 202, 204, and is connectedto the busbars 202, 204 using a low inductive laminated connection. Thebulk capacitor 116 also provides an electrical link to the vertical bus202, 204.

The inverter stack assembly shown in FIG. 2 may be more modular than theinverter stack assembly shown in FIG. 1 (e.g., additional phase moduleassemblies can be easily attached to the busbars 202, 204), may beeasier to manufacture than the inverter stack assembly shown in FIG. 1(e.g., due to the modular nature), may be easier to transport than theinverter stack assembly shown in FIG. 1 (e.g., due to the modularnature, the inverter stack assembly shown in FIG. 2 may be taken apartand re-assembled more easily than the inverter stack assembly shown inFIG. 1), may be lighter for individual components relative to theinverter stack assembly shown in FIG. 1, and may have a simpler assemblyprocess than the inverter stack assembly shown in FIG. 1.

FIG. 3 illustrates a circuit diagram of an electrical power system 300of a vehicle. The power system 300 includes two of the inverter stackassemblies 200 shown in FIG. 2 (“Stack 1” and “Stack 2” in FIG. 3). Arectifier 302 is fed from a multi-phase AC power supply 304, such as asynchronous generator (not shown) or another type of power supply. Thepower supply provides a three phase AC current in the illustratedembodiment, but optionally can provide another AC current having atleast two phases. The output of the rectifier (which could be a diodebridge or another component) is split into two sets of DC+/DC− feedingpoints 306, 308, each of which supplies a system of the laminatedbusbars 202, 204 (also shown in FIG. 2) arranged in two stacks,represented as vertical columns in FIG. 3. Horizontal dispositions andvariations of the laminated busbars 202, 204 can be used in analternative embodiment. The interconnection elements between the outputand the rectifier could be a pair of cables, busbars, or otherconductive bodies or pathways. The two stacks are receptacles for anumber of the phase module assemblies (shown in FIG. 1), as shown inFIG. 3. Each of the inverter stack assemblies or at least one of theinverter stack assemblies shown in FIG. 2 can receive the DC currentfrom the busbars.

In the illustrated embodiment, the multiple (e.g., three) phase AC thatis output by at least one of the inverter assemblies (e.g., the inverterassembly in FIG. 3, but optionally can be another inverter assembly) canbe provided to a load 310, such as a motor of a vehicle or another load.This multi-phase AC that is output to the load can power the load, suchas by powering the motor to generate tractive effort at a wheel, axle,or the like, of the vehicle, by powering the motor to rotate a propellerof a marine vessel, or the like.

Each inverter stack assembly in FIG. 3 holds eight phase moduleassemblies, represented to the left of the respective stack assembly.The phase module assemblies are arranged in two sets of three contiguousphase module assemblies, which together form a three-phase inverterassembly. The left stack assembly is capable of feeding two three-phaseAC loads, such as motors. There are two additional positions for housingphase module assemblies, in positions four (where the chopper islocated) and eight (where the auxiliary inverter assembly is located),with the positions numbered in an order counting from the top.

In the illustrated embodiment, the phase module assembly 114 forming thechopper 112 of position four holds switches used to transfer power to aresistor (e.g., a grid box block), which can be used, for example,during braking of a vehicle or when excess voltage transiently appearsin the system 300 which needs to be quickly dissipated. The phase moduleassembly 114 forming the auxiliary inverter assembly 100 in positioneight can be used for some auxiliary function, such as driving anotherbrake resistor, generating part of a chopped waveform to create asecondary bus at a different voltage level to feed additional inverterassemblies (not shown) used to drive auxiliary loads, or the like.Although eight phase module assemblies 114 are shown in each stack 200,more could be used in one or more of the stacks 200. In the illustratedembodiment, the two stacks 200 together allow up to four independentloads (e.g., motors) to be powered, such as traction motors of afour-wheeled vehicle.

FIG. 4 illustrates a circuit diagram of one embodiment of the phasemodule assembly 114 shown in FIGS. 2 and 3. FIG. 5 illustrates aperspective view of one embodiment of the phase module assembly 114shown in FIGS. 2 through 4. The phase module assembly 114 includes aseries connection of multiple (e.g., two) switches 400, 402 (“IGBT1” and“IGBT2” in FIG. 4. Each switch 400, 402 can be a packaged insulativegate bipolar transistor (IGBT) with antiparallel diodes integrated in ahousing, or another type of solid state, semiconductor-based device.

The phase module assembly 114 includes a first flat busbar 500 that iselongated along a first direction 502. For example, the busbar 500 maybe planar or substantially planar (e.g., at least 75% of the busbar 500lies within the same two-dimensional plane), and may be longer in thefirst direction 502 than any other direction. The busbar 500 can beformed from several conductive plates (or busbars) 504, 506, 700 thatare laminated together, or may be formed as a single plate. As shown inFIG. 4, the busbar 506 can operate as or be conductively coupled withthe collector of the IGBT 400. The busbar 700 can operate as or beconductively coupled with the emitter of the IGBT 400, and also with thecollector of the IGBT 402. The plate 504 terminates in a downwardly bentconductive tab 508, which can be used to connect with a cable or otherconnection to the load 310 (such as a cable to a motor) to output thephase of the AC current created by the phase module assembly 114. Asshown, the plates 504, 506 at least partially overlap each other, butmay not entirely overlap each other.

The busbar 500 includes internal positive and negative terminalconnectors or bushings 510, 512 and phase output terminal connectors orbushings 514. The connectors 510, 512, 514 are coupled with componentsinternal to the phase module assembly 114, such as different parts ofthe switches 400, 402 forming the phase module assembly 114.

The phase module assembly 114 includes a second flat busbar 516 that isconductively coupled with the first flat busbar 500. The second flatbusbar 516 extends in a plane that is orthogonal to the first direction502 of the first flat busbar 500 and that is orthogonal to the plane inwhich the first flat busbar 500 extends. For example, as shown in FIG.5, the busbars 500, 516 may extend in perpendicular planes. In oneembodiment, the phase module assembly 114 is oriented such that thesecond busbar 516 is oriented vertically while the first busbar 500 isoriented horizontally. The second busbar 516 can be referred to as avertical busbar and the first busbar 500 can be referred to as ahorizontal busbar in such an orientation.

The busbar 516 includes external positive and negative bushings 518,520. These bushings 518, 520 are configured to be conductively coupledwith the power source 304, such as by being coupled with the busbar 202or 204 to receive the DC. The internal positive and negative terminalconnectors 510, 512 are conductively coupled with the external positiveand negative bushings 518, 520 inside the busbars 500, 516 and othercomponents of the assembly 114 (e.g., by conductive plates, traces,buses, or the like) so that the assembly 114 receives the DC from thepower source 304, converts the DC into one phase of the multi-phase AC,and outputs the phase of the multi-phase AC to the load 310 (e.g., viathe tab 508). In the illustrated embodiment, the bushings 518, 520 aresymmetrically arranged on different parts of the same surface or side ofthe vertical busbar 516 (e.g., top and bottom portions of the side thatis visible in FIG. 5).

With continued reference to the phase module assembly 114 shown in FIG.5, FIG. 6 illustrates a perspective view of the inverter stack assembly200 shown in FIG. 2 and FIG. 7 illustrates a closer view of the top ofthe inverter stack assembly 200 shown in FIG. 6. When viewed from thefront (e.g., in FIGS. 5 and 6) the laminated phase module assembly 114exits to the right of the stack 200, protrudes a certain distance, andis shaped outside the top of the switches toward the front right andends in the bushings 518, 520 for DC+ and DC− (depending on the ampacityrequirements of the system). The phase module assembly 114 can beenclosed inside an exterior housing 600. This can protect the phasemodule assembly 114 against the environment, dust, and other elements.

In one embodiment, the phase module assembly 114 includes or isconnected with a heat sink beneath the flat busbar 500 (e.g., in theperspective of FIGS. 4 through 6). FIG. 8 illustrates a top view of oneembodiment of the switches 400, 402 of the phase module assembly 114connected with a heat sink 702. FIG. 9 illustrates a side view of theheat sink 702 shown in FIG. 8. The switches 400, 402 can be IGBTs thatare electrically connected to the terminals 512, 510 and the phasemodule busbar laminations, and are thermally connected through lowerbaseplates of the switches 400, 402 to a heat sink 702.

Baseplates 800 of the switches 400, 402 can be coupled with (e.g.,screwed down onto) the heat sink 702. The heat sink 702 includes severalspaced-apart fins 704 that allow air to flow between the fins 704 andbeneath the phase module assembly 114. In the perspective of FIG. 7, thefins 704 are elongated in up-and-down directions and are spaced apart inlateral or side-to-side directions. Air can enter the heat sink 702(e.g., enter the spaces between the fins 704) from the back (e.g., fromthe top side of FIG. 7) from a backside plenum and flow through thefinned channels in the heat sink 702 toward the front (e.g., the bottomside of FIG. 7). The hot air between the fins 704 exits from the frontthrough ducted outputs to the outside of a cabinet where the stack 200is placed. Seals can be provided to avoid air leaks at the back andfront sides where air comes in and goes out. In one embodiment, currentflows (or is conducted) in the busbar 500 of the phase module assembly114 in a direction that is orthogonal to the directions in which airflows between the fins 704 in the heat sink 702.

The phase module assembly 114 can include an electrical interface thatadapts logical signals from a controller to voltage signals needed toswitch on and off the switches 400, 402 with adequate transients (e.g.,this provides the functionality of a multi-switch gate driver). In oneembodiment, each of the switches 400, 402 can include or represent agate driver. Each of the switches 400, 402 are disposed side-by-sidethrough interconnecting harnesses that are screwed to control terminalsof the switches 400, 402. The switches 400, 402 can receive power supplyand logic control signals, such as through fiber optic connectors.

FIG. 10 illustrates a cross-sectional view of one embodiment of thephase module assembly 114 disposed inside the exterior housing 600. Thephase module assembly 114 can connect with the busbar 202 or 204described above. For example, the plate 506 can be conductively coupledwith one side of the busbar 202 or 204 and the switches 400, 402 can beconductively coupled with the opposite side of the busbar 202 or 204.The positive internal bushings 510 can conductively couple the plate 506and the positive external bushings 518 with the busbar 202 or 204 toconduct the positive DC being conducted by the busbar 202 or 204. Thenegative internal bushings 512 can conductively couple the switches 400,402 and the negative external bushings 520 with the busbar 202 or 204 toconduct the negative DC being conducted by the busbar 202 or 204.

One feature of the phase module assembly 114 is that the busbar 516 isshaped and positioned to avoid collision with capacitors placed insideboxes at the back of the vertical busbar 516. FIG. 11 illustrates aperspective view of one embodiment of a back side of the vertical busbar516 shown in FIG. 5. The side of the busbar 516 shown in FIG. 11 isopposite of the side of the busbar 516 that is visible in FIGS. 6 and 7.

The busbar 516 includes two capacitor boxes 1100, 1102 on each side ofthe busbar 516. The capacitor boxes 1100, 1102 house a capacitor 1104that are conductively coupled with the busbar 516 by several feet 1106.The boxes 1100, 1102 form exterior housings that protect the capacitor1104 located therein. The capacitors 1104 can be a low inductancecapacitor. The capacitor 1104 can be a wound foil capacitor or anothertype of capacitor.

The capacitor 1104 can be a low inductance capacitor when the entireflat vertical busbar 516 with the capacitor 1104 behaves as acommutation capacitor for the switches. For example, for IHM 19×14modules, 3.3 kV blocking, and four mounted capacitors 1104, eachcapacitor 1104 may be less than 50 nH. Alternatively, the low inductancecapacitors 1104 may have inductances of less than 50 μH or less than 50mH. The boxes 1100, 1102 may not alone guarantee a perfect protectedenvironment for the capacitors 1104 over time. An insulation barrier canbe added to improve on the sealing of the boxes 1100, 1102 to reduce orprevent creepage failures.

As also shown in FIG. 11, the capacitors 1104 may include conductivecrowns 1200 that project in opposite directions from the vertical busbar516. Although only one crown 1200 is visible in FIG. 11, another crown1200 may be disposed on and project from the opposite side of thevertical busbar 516.

The crowns 1200 may have cylindrical shapes. Each of the conductivecrowns 1200 can be conductively coupled with the vertical busbar 516 byconductive feet 1106. The conductive feet 1106 can conductively couplethe crown 1200 with the conductive busbar or plate 506, while otherconductive feet can conductively couple the other crown 1200 with thebusbar or plate 506. One crown 1200 is coupled to one side of thevertical busbar 516, while the other crown is coupled to the oppositeside of the vertical busbar 516. Each conductive foot can be an L-shaped(or other shape) body that is fastened to the vertical busbar 516 (e.g.,by fasteners, such as a bolt or screw) and that is coupled with one ofthe crowns.

The capacitors 1104 include dielectric bodies disposed between theconductive crowns and the vertical busbar. For example, one dielectricbody is located between one crown and one side of the vertical busbar,while another dielectric body is located between the other crown and theopposite side of the vertical busbar. The combination of the dielectricbodies between the crowns forms two capacitors, with one capacitor oneach side of the busbar. For example, one capacitor can be formed by onecrown and the conductive plate, which are not conductively coupled witheach other but are separated from each other by one of the dielectricbodies. The other capacitor can be formed by the other crown and theconductive plate, which also are not conductively coupled with eachother but are separated from each other by the other dielectric body.

The current conducted in or by the busbar or plate 506 can be conductedinto each of the crowns, which are separated from each other by thedielectric bodies. The busbar or plate can include plural planarconductors, e.g., laminated conductive plates. One of these can operateor act as a ground plate or ground reference of the capacitor. Forexample, current conducted in or through one laminated plate (e.g.,which is coupled with the collector of the switch 400) can be conductedinto the crowns in each capacitor, and the current conducted in orthrough another laminated plate (e.g., which is coupled with the emitterof the switch 400 and the collector of the switch 402) can be conductedwith the other crown. This forms a capacitor that is integrated into thestructure of the busbar and does not require separate connections withthe switches 400, 402. Alternatively, the capacitors can form a singlecapacitor. For example, one laminated plate can be conductively coupledwith one crown (e.g., by the feet 1106), while the other laminated plateis conductively coupled with the other crown.

FIG. 12 is a schematic illustration of a vehicle 1600. The vehicle caninclude one or more embodiments of the electrical power system that aredescribed herein. The vehicle includes a body 1602, such as a vehiclechassis, hull, frame, or the like, that supports components, cargo, andpassengers of the vehicle as the vehicle moves along one or more routes.While the vehicle is shown as a land-based vehicle having wheels,alternatively, the vehicle can represent a marine vessel. An electricalpower supply system 1606 represents one or more of the electrical powersystems described herein, and is located onboard the body of thevehicle. The body also supports one or more propulsion loads 1608, suchas one or more traction motors that rotate wheels of the vehicle, one ormore motors that rotate a propeller of the vehicle, or the like.Optionally, the body supports one or more auxiliary loads 1610, such asloads that do not perform work to propel the vehicle. The propulsionload(s) can represent one or more of the loads 310. A power source 1612onboard the vehicle body can represent the power source 304. Theelectrical power system can operate as described herein to convert DCfrom the power source into AC that powers one or more of the propulsionloads and/or auxiliary loads.

In embodiments, the vehicle may be relatively large, such as a 50 ton,100 ton, 250 ton, or 400+ ton mining haul truck, or a 40+ ton bollardpull tug boat. The inverter and/or electrical power system may beconfigured to output, in at least one mode of operation, from 10 kW to3000 kW, or more. This reflects that in embodiments, the power system orinverter includes relatively large, high-power electronic components(power transistors or the like) that operate at relatively high powerlevels (tens of amperes and hundreds of volts or more), for poweringlarge loads (e.g., traction motors) for propulsion of vehicles of thismagnitude. In one aspect, the term “haul vehicle” refers to a vehiclewith at least a 50 ton hauling capacity (land) or 40 ton bollard pull(marine).

In one embodiment, a phase module assembly of a multi-phase inverter isprovided. The assembly includes a first flat laminated busbar elongatedalong a first direction, including a positive layer, a negative layer,and a load layer configured to be conductively coupled with a load. Thefirst flat laminated busbar includes internal positive and negativeterminal connectors for connecting the first flat laminated busbar to asecond laminated flat busbar. The second laminated flat busbar includespositive and negative layers extending in a plane that is orthogonal tothe first direction of the first laminated flat busbar. The secondlaminated flat busbar includes external positive and negative bushingsconfigured to be conductively coupled with a power source of directcurrent. The internal positive and negative terminal connectors areconductively coupled with the external positive and negative bushings toreceive the direct current from the power source. The assembly alsoincludes one or more transistors conductively coupled with the internalpositive and negative terminal connectors and configured to convert thedirect current into one phase of a multi-phase alternating current ofthe multi-phase inverter, and to output the phase of the multi-phasealternating current to the load. The assembly also includes one or morecapacitors conductively coupled with the internal positive and negativeterminal connectors and with the external positive and negative bushingsconfigured to be conductively coupled with the power source of directcurrent.

Optionally, the one or more capacitors are mechanically mounted on thesecond flat busbar.

Optionally, the one or more capacitors are one or more low inductancecapacitors.

Optionally, the external positive and negative bushings aresymmetrically arranged to one side of the one or more capacitors.

Optionally, each of the one or more capacitors includes a conductivecrown coupled with the second flat busbar by one or more conductive feetand a dielectric body disposed between the conductive crown and thesecond flat busbar.

Optionally, each of the one or more conductive feet is an L-shaped bodythat is fastened to the second flat busbar and is coupled with theconductive crown of the corresponding capacitor.

Optionally, the first flat laminated busbar is coupled with a heat sinkconfigured to be disposed between the first flat laminated busbar and aswitch to which the internal positive and negative terminal connectorsare coupled

Optionally, the heat sink includes elongated fins arranged to directairflow between the fins in directions that are perpendicular todirections in which current is conducted within the positive andnegative layers of the first flat laminated busbar.

Optionally, the assembly also includes one or more switches and ahousing that encloses the first flat laminated busbar, the one or moreswitches, and the heat sink.

Optionally, the first flat laminated busbar includes a bent tab disposedat an end of the first flat laminated busbar that is opposite of an endof the first flat laminated busbar that is coupled with the second flatlaminated busbar.

Optionally, the bent tab is configured to be conductively coupled withthe load.

In one embodiment, a multi-phase inverter assembly includes two or moreof the phase modules conductively coupled with the power source toseparately receive different portions of the direct current and toseparately generate different phases of the multi-phase alternatingcurrent for the load.

Optionally, the two or more phase modules are coupled with a joiningbusbar that is configured to be conductively coupled with one or morebulk capacitors and one or more external cables of the power source.

In one embodiment, a multi-phase inverter stack includes the multi-phaseinverter assembly, and the joining busbar.

In one embodiment, a power supply system includes a plurality of themulti-phase inverter stacks.

Optionally, the power supply system also includes an interconnectinglamination coupled with one or more of a top one of the multi-phaseinverter assembly of the multi-phase inverter stacks, a bottom one ofthe multi-phase inverter assembly of the multi-phase inverter stacks, orthe joining busbar.

Optionally, the load includes one or more of a vehicle brake resistor ora vehicle motor.

In one embodiment, a vehicle is provided that includes a chassis orhull, and a vehicle electrical power system operably disposed onboardthe chassis or hull. The power system includes a vehicle electrical loadthat comprises at least one of a vehicle motor or a braking resistor.The power system also includes a phase module assembly of a multi-phaseinverter. The phase module assembly includes a first flat laminatedbusbar elongated along a first direction, including a positive layer, anegative layer, and a load layer configured to be conductively coupledwith the load. The first flat laminated busbar includes internalpositive and negative terminal connectors for connecting the first flatlaminated busbar to a second laminated flat busbar. The second laminatedflat busbar includes positive and negative layers extending in a planethat is orthogonal to the first direction of the first laminated flatbusbar. The second laminated flat busbar includes external positive andnegative bushings configured to be conductively coupled with a powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assembly also includes one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assembly also includesone or more capacitors conductively coupled with the internal positiveand negative terminal connectors and with the external positive andnegative bushings configured to be conductively coupled with the powersource of direct current.

Optionally, the one or more capacitors are mechanically mounted on thesecond flat busbar

Optionally, the one or more capacitors are one or more low inductancecapacitors.

Optionally, the external positive and negative bushings aresymmetrically arranged to one side of the one or more capacitors.

Optionally, each of the one or more capacitors includes a conductivecrown coupled with the second flat busbar by one or more conductive feetand a dielectric body disposed between the conductive crown and thesecond flat busbar.

Optionally, each of the one or more conductive feet is an L-shaped bodythat is fastened to the second flat busbar and is coupled with theconductive crown of the corresponding capacitor.

Optionally, the first flat laminated busbar is coupled with a heat sinkconfigured to be disposed between the first flat laminated busbar and aswitch to which the internal positive and negative terminal connectorsare coupled.

Optionally, the heat sink includes elongated fins arranged to directairflow between the fins in directions that are perpendicular todirections in which current is conducted within the positive andnegative layers of the first flat laminated busbar.

Optionally, the vehicle also includes one or more switches and a housingthat encloses the first flat laminated busbar, the one or more switches,and the heat sink.

Optionally, the first flat laminated busbar includes a bent tab disposedat an end of the first flat laminated busbar that is opposite of an endof the first flat laminated busbar that is coupled with the second flatlaminated busbar.

In one embodiment, a vehicle power supply system includes plural phasemodule assemblies each including a first flat laminated busbar elongatedalong a first direction, including a positive layer, a negative layer,and a load layer configured to be conductively coupled with a vehicleload. The first flat laminated busbar includes internal positive andnegative terminal connectors for connecting the first flat laminatedbusbar to a second laminated flat busbar. The second laminated flatbusbar includes positive and negative layers extending in a plane thatis orthogonal to the first direction of the first laminated flat busbar.The second laminated flat busbar includes external positive and negativebushings configured to be conductively coupled with a vehicle powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assemblies also include one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assemblies alsoinclude one or more capacitors conductively coupled with the internalpositive and negative terminal connectors and with the external positiveand negative bushings configured to be conductively coupled with thepower source of direct current. The phase module assemblies areconductively coupled with the power source to separately receivedifferent portions of the direct current and to separately generatedifferent phases of the multi-phase alternating current for the load.

Optionally, the phase module assemblies are coupled with a joiningbusbar that is configured to be conductively coupled with one or morebulk capacitors and one or more external cables of the power source.

In one embodiment, a vehicle power supply system includes plural phasemodule assemblies each including a first flat laminated busbar elongatedalong a first direction, including a positive layer, a negative layer,and a load layer configured to be conductively coupled with a vehicleload. The first flat laminated busbar includes internal positive andnegative terminal connectors for connecting the first flat laminatedbusbar to a second laminated flat busbar. The second laminated flatbusbar includes positive and negative layers extending in a plane thatis orthogonal to the first direction of the first laminated flat busbar.The second laminated flat busbar includes external positive and negativebushings configured to be conductively coupled with a vehicle powersource of direct current. The internal positive and negative terminalconnectors are conductively coupled with the external positive andnegative bushings to receive the direct current from the power source.The phase module assemblies also include one or more insulated gatebipolar transistors conductively coupled with the internal positive andnegative terminal connectors and configured to convert the directcurrent into one phase of a multi-phase alternating current of themulti-phase inverter, and to output the phase of the multi-phasealternating current to the load. The phase module assemblies alsoinclude one or more capacitors conductively coupled with the internalpositive and negative terminal connectors and with the external positiveand negative bushings configured to be conductively coupled with thepower source of direct current. The phase module assemblies areconductively coupled with the power source to separately receivedifferent portions of the direct current and to separately generatedifferent phases of the multi-phase alternating current for the load.The phase module assemblies also include a joining busbar connecting thephase module assemblies and configured to be conductively coupled withone or more bulk capacitors and one or more external cables of the powersource.

Optionally, the joining busbar is a laminated busbar located between thephase module assemblies.

Optionally, the load includes one or more of a vehicle brake resistor ora vehicle motor.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventivesubject matter without departing from its scope. While the dimensionsand types of materials described herein are intended to define theparameters of the inventive subject matter, they are by no meanslimiting and are exemplary embodiments. Many other embodiments will beapparent to one of ordinary skill in the art upon reviewing the abovedescription. The scope of the inventive subject matter should,therefore, be determined with reference to the appended clauses, alongwith the full scope of equivalents to which such clauses are entitled.In the appended clauses, the terms “including” and “in which” are usedas the plain-English equivalents of the respective terms “comprising”and “wherein.” Moreover, in the following clauses, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112(f), unless and until such claim limitations expresslyuse the phrase “means for” followed by a statement of function void offurther structure.

This written description uses examples to disclose several embodimentsof the inventive subject matter, including the best mode, and also toenable one of ordinary skill in the art to practice the embodiments ofinventive subject matter, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe inventive subject matter is defined by the claims, and may includeother examples that occur to one of ordinary skill in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal languages of the claims.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or operations, unless such exclusion is explicitlystated. Furthermore, references to “one embodiment” of the presentinvention are not intended to be interpreted as excluding the existenceof additional embodiments that also incorporate the recited features.Moreover, unless explicitly stated to the contrary, embodiments“comprising,” “comprises,” “including,” “includes,” “having,” or “has”an element or a plurality of elements having a particular property mayinclude additional such elements not having that property.

What is claimed is:
 1. A phase module assembly of a multi-phaseinverter, the phase module assembly comprising: a first laminated busbarincluding a first positive layer, a first negative layer, and a loadlayer configured to be conductively coupled with a vehicle load, thefirst laminated busbar including internal positive and negative terminalconnectors for connecting the first laminated busbar to a secondlaminated busbar, the second laminated busbar including a secondpositive layer and a second negative layer extending orthogonally to thefirst laminated busbar, the second laminated busbar including externalpositive and negative bushings configured to be conductively coupledwith a power source of direct current; one or more transistorsconductively coupled with the internal positive and negative terminalconnectors of the first laminated busbar, the one or more transistorsconfigured to convert the direct current into a phase of alternatingcurrent of the multi-phase inverter, and to output the phase of thealternating current to the vehicle load; and one or more capacitorsconductively coupled with the internal positive and negative terminalconnectors of the first laminated busbar, conductively coupled with theexternal positive and negative bushings, and configured to beconductively coupled with the power source of the direct current.
 2. Thephase module assembly of claim 1, wherein the one or more capacitors aremounted on the second laminated busbar.
 3. The phase module assembly ofclaim 1, wherein the one or more capacitors are one or more lowinductance capacitors.
 4. The phase module assembly of claim 1, whereinthe external positive and negative bushings are symmetrically arrangedto one side of the one or more capacitors.
 5. The phase module assemblyof claim 1, wherein each of the one or more capacitors includes aconductive crown coupled with the second laminated busbar by one or moreconductive feet and a dielectric body disposed between the conductivecrown and the second laminated busbar.
 6. The phase module assembly ofclaim 5, wherein each of the one or more conductive feet is an L-shapedbody that is fastened to the second laminated busbar and is coupled withthe conductive crown of the corresponding capacitor.
 7. The phase moduleassembly of claim 1, wherein the first laminated busbar is coupled witha heat sink configured to be disposed between the first laminated busbarand a switch to which the internal positive and negative terminalconnectors are coupled.
 8. The phase module assembly of claim 7, whereinthe heat sink includes elongated fins arranged to direct airflow betweenthe fins in directions that are perpendicular to directions in which thedirect current is conducted within the first positive layer and thefirst negative layer of the first laminated busbar.
 9. The phase moduleassembly of claim 7, further comprising one or more switches and ahousing that encloses the first laminated busbar, the one or moreswitches, and the heat sink.
 10. The phase module assembly of claim 1,wherein the first laminated busbar includes a bent tab disposed at anend of the first laminated busbar that is opposite of an end of thefirst laminated busbar that is coupled with the second laminated busbar.11. The phase module assembly of claim 1, wherein the internal positiveand negative terminal connectors are conductively coupled with theexternal positive and negative bushings to receive the direct currentfrom the power source.
 12. A vehicle power supply system comprising: aphase module assembly including: a first laminated busbar having atleast a first positive layer, a first negative layer, and a load layerconfigured to be conductively coupled with a vehicle load, the firstlaminated busbar including positive and negative terminal connectors forconnecting the first laminated busbar to a second laminated busbar, thesecond laminated busbar including a second positive layer and a secondnegative layer orthogonally oriented relative to the first laminatedbusbar, the second laminated busbar including positive and negativebushings configured to be conductively coupled with a vehicle powersource of direct current, wherein the positive and negative terminalconnectors are conductively coupled with the positive and negativebushings to receive the direct current from the vehicle power source;one or more transistors conductively coupled with the positive andnegative terminal connectors and configured to convert the directcurrent into a phase of a multi-phase alternating current of amulti-phase inverter, and to output the phase of the multi-phasealternating current to the vehicle load; and one or more capacitorsconductively coupled with the positive and negative terminal connectorsand with the positive and negative bushings configured to beconductively coupled with the vehicle power source of the directcurrent.
 13. The vehicle power supply system of claim 12, wherein thephase module assembly is coupled with a joining busbar that isconfigured to be conductively coupled with one or more bulk capacitorsand one or more external cables of the vehicle power source.
 14. Thevehicle power supply system of claim 13, wherein the vehicle load is atraction motor for a haul vehicle.
 15. A vehicle power supply systemcomprising: plural phase module assemblies each including: a firstlaminated busbar including a first positive layer, a first negativelayer, and a load layer configured to be conductively coupled with avehicle load, the first laminated busbar including internal positive andnegative terminal connectors for connecting the first laminated busbarto a second laminated busbar, the second laminated busbar including asecond positive layer and a second negative layer orthogonally orientedto the first laminated busbar, the second laminated busbar includingexternal positive and negative bushings configured to be conductivelycoupled with a vehicle power source of direct current, wherein theinternal positive and negative terminal connectors are conductivelycoupled with the external positive and negative bushings to receive thedirect current from the vehicle power source; one or more transistorsconductively coupled with the internal positive and negative terminalconnectors and configured to convert the direct current into a phase ofa multi-phase alternating current of a multi-phase inverter, and tooutput the phase of the multi-phase alternating current to the vehicleload; and one or more capacitors conductively coupled with the internalpositive and negative terminal connectors and with the external positiveand negative bushings configured to be conductively coupled with thevehicle power source of the direct current; and a joining busbarconnecting the phase module assembly and configured to be conductivelycoupled with one or more bulk capacitors and one or more external cablesof the vehicle power source.
 16. The vehicle power supply system ofclaim 15, wherein the joining busbar is a third laminated busbar. 17.The vehicle power supply system of claim 15, wherein the vehicle loadincludes one or more of a vehicle brake resistor or a vehicle motor. 18.The vehicle power supply system of claim 15, wherein the vehicle load isa traction motor for a haul vehicle.
 19. The vehicle power supply systemof claim 15, wherein the phase module assemblies are conductivelycoupled with the vehicle power source to separately receive differentportions of the direct current.
 20. The vehicle power supply system ofclaim 15, wherein teach of the phase module assemblies is configured togenerate a different phase of the multi-phase alternating current forthe vehicle load.